DESIGN FOR SIX SIGMA

Six Sigma Alchemy (P) Ltd. (SSA) has been pioneering in Six Sigma Consulting in India since 1999. Apart from the Classical Six Sigma, and Lean Six Sigma implementations in the industry, SSA also consults for DFSS or Design for Six Sigma.

World-wide there are 4 approaches to the practice of 'Six Sigma'.

Classical Six Sigma or 'Six Sigma' as is commonly known is more effective to solve problems of manufacturing set ups. Classical Six Sigma applies the DMAIC- Define, Measure, Analyze, Improve & Control - methodology. The application of this methodology assumes that a process pre-exists its application, and the existing process is not able to deliver the desired results. The entire methodology aims at elimination of defect from the process.

Lean Six Sigma focuses on resource conservation and optimization. It creates Lean process to produce optimal results. It combines the best of 'Classical Six Sigma' and 'Lean Concepts'. The entire methodology aims at defect elimination plus resource optimization.

Both the above approaches focus on existing processes.

DMADV [or Define, Measure, Analyze, Develop & Verify] is another methodology for Six Sigma that questions the existing design of the product for possible design solutions for reducing defects and improving Customer satisfaction. Unlike Classical Six Sigma and Lean Six Sigma that do not look into the product design, Six Sigma through DMADV looks into the product design for possible product modifications.

Design for Six Sigma [DFSS] is a "rigorous approach to designing products, services, and/ or processes to reduce delivery time, development cost, increase effectiveness, and better satisfy the customers." It is applied for new product/ process development, in a situation when no product or process exists. It is applied to ensure zero defect, and develop 'first time right' product/ processes. Unlike Classical Six Sigma and Lean Six Sigma that is applied to existing processes, DFSS is applied when the design is in the drawing board stage. It is an in- advance Quality Planning tool.

Following is the basic procedure applied to DFSS:

	IDENTIFY the customer requirements
	Analyze & Prioritize the requirements
	develop a DESIGN
	Map or document the requirements in a flow running down from the system level to sub systems, components, and processes
	OPTIMIZE or track the capability of the product/ service and process at each step;
	Highlight the gaps between the requirements and capabilities, to make the processes actionable.
	VERIFY & establish control plan.

DFSS Design Process